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Edit Comment Close Premium member Presentation Transcript Micro Gear Manufacturing : Micro Gear Manufacturing Troy Anderson Joseph Clausen Michael South ME 324 Section B Group 21 Overview : Overview Introduction Applications Manufacturing Processes Conclusion Micro Gear Specifications : Micro Gear Specifications Required Specifications for Micro Gears Less than 10 mm diameter Have sufficient load bearing strength Able to transmit mechanical forces and movements Introduction to Micro Gears : Introduction to Micro Gears Applications Pumps Watches Harmonic Drives RC Vehicles Medical Equipment Processes Gear Hobbing Metal Injection Molding Wire Electrical Discharge Machining Micro Pumps : Micro Pumps Usually made of plastics and sometimes metals depending on fluid usage Precise flow rate Highly efficient Conserve liquids in the system Can handle flow rates of up to 300 ml/min Allows pumps to dispense volumes as little as 0.25 µL Watches : Watches A set of micro gears inside watches are used along with springs to control the rate at which the hands of the watch rotate. Made out of various metals such as copper and steel. Works by converting potential energy of a spring into kinetic energy of a gear Uses gear ratios to keep time on a scale in minutes and seconds. Micro Gears Harmonic Drives : Micro Gears Harmonic Drives Advantages Accuracy Speed Reliability Robustness Versatility Key Features Zero Backlash Lifetime Lubrication Pre-loaded bearings for support Excellent protection against corrosion Manufacturing Micro Gears : Manufacturing Micro Gears Three methods to produce micro gears Gear Hobbing Metal Injection Molding (MIM) Wire Electrical Discharge Machining (WEDM) Hobbing : Hobbing Common process used to manufacture gears, splines, and sprockets. Cutting tool called a Hob is used to machine the gear Two spindles ,holding the hob and blank, are held at a non parallel angle. Both spindles are spun with the hob spinning at a faster, predetermined, ratio. Ex 40:1 Large gears have to be “gashed” or the rough shape cut to make hobbing easier. Hobbing : Hobbing Advantages Established industry. High quality parts. Tolerances in the hundreds of thousands can be manufactured. Disadvantages Coolant must be used, however, new process may eliminate the need for coolant. Machines are generally large and making micro gears can be expensive. Hobbing Video : Hobbing Video Metal Injection Molding MIM : Metal Injection Molding MIM Metal powder is mixed with a thermoplastic binder. Intensive mixing is required to produce high quality “feed stock”. Conventional injection molding process feed material under pressure and temp into one or more molds. Two thermo processes are used to finish the part. A de-binding process removes the binding agent from the compact part. A sintering process (heating below melting point) finishes the final part. Predictable and linear shrinking of the part occurs between 18 to 25% of original size. Metal Injection Molding MIM : Metal Injection Molding MIM Advantages High tolerances Material purity effectively retained Can produce small parts otherwise unattainable by regular machining practice Fully able to integrate robotics for large production runs Disadvantages High machine costs High part costs for low quantity runs Complicated processes Wire Electrical Discharge Machining : Wire Electrical Discharge Machining Uses a wire that caries a current contained in a dielectric fluid Accurate to .004 mm Smallest diameter wire 20 µm with precision of ± 1 µm Uses de-ionized water as the dielectric fluid, this helps flush away cutting debris Multi access electrodes allow for the creation of intricate shapes Well suited for the manufacturing of micro gears Wire Electrical Discharge Machining : Wire Electrical Discharge Machining Advantages Complex shapes Cuts very hard materials Indirect contact between cutter and work piece Thin or flexible material can be machined Disadvantages Slow cutting rate High power consumption Electrode wear makes reproducing Sharp corners difficult Wire Electrical Discharge Machining video : Wire Electrical Discharge Machining video Conclusion : Conclusion Technology has been in use for around 100 years Desire for smaller products has increased demand Advancements in technology allow for smaller more precise gears You do not have the permission to view this presentation. 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